Abrasive webs and methods of making the same

ABSTRACT

The present invention is directed to abrasive webs, composite materials, and methods of making abrasive webs and composite materials.

FIELD OF THE INVENTION

[0001] The present invention relates to abrasive webs, compositematerials, and methods of making such webs and composite materials.

BACKGROUND OF THE INVENTION

[0002] There is a need in the art for webs and composite materialshaving one or more of the following properties:

[0003] (1) desired abrasiveness;

[0004] (2) desired absorbency;

[0005] (3) desired bulkiness;

[0006] (4) desired softness; and

[0007] (5) desired scent or aroma.

SUMMARY OF THE INVENTION

[0008] The present invention is directed to abrasive webs and nonwovencomposite materials. The abrasive webs and nonwoven composite materialsmay comprise one or more layers, wherein each layer provides desiredproperties to the web or composite material. In one exemplary embodimentof the present invention, the abrasive web comprises a first meltblownnonwoven web bonded to a second fabric, wherein the meltblown nonwovenweb/fabric composite is differentially microstretched in its crossdirection to produce a composite material having greater bulk, softnessand drapeability relative to the pre-stretched composite material.

[0009] The present invention is further directed to methods of makingabrasive webs and nonwoven composite materials having desiredproperties, and various uses for the abrasive webs and nonwovencomposite materials.

[0010] These and other features and advantages of the present inventionwill become apparent after a review of the following detaileddescription of the disclosed embodiments and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The present invention is further described with reference to theappended figures, wherein:

[0012]FIG. 1 depicts exemplary components for abrasive webs and nonwovencomposite materials of the present invention;

[0013]FIG. 2 depicts an exemplary bonded composite of the presentinvention;

[0014]FIG. 3 depicts an exemplary cross-sectional configuration of thebonded composite of FIG. 2 as viewed along line A-A;

[0015]FIG. 4 depicts an exemplary process for making a meltblown web foruse in the abrasive webs and nonwoven composite materials of the presentinvention;

[0016]FIG. 5 depicts a variation of the exemplary process shown in FIG.4, wherein a second layer is joined to the meltblown web layer;

[0017]FIG. 6 depicts another exemplary process for making abrasive websand nonwoven composite materials of the present invention;

[0018]FIG. 7A depicts an exemplary stretching process for stretching anonwoven composite material or one or more layers of the nonwovencomposite material;

[0019]FIG. 7B depicts a cross-sectional view of the apparatus used inthe stretching process of FIG. 7A; and

[0020]FIGS. 8A and 8B depict exemplary cross-sectional configurationsfor composite materials of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0021] The present invention is directed to abrasive webs and nonwovencomposite materials having desired properties. The abrasive webs andnonwoven composite materials possess one or more of the followingproperties: (1) desired abrasiveness; (2) desired absorbency; (3)desired bulkiness; (4) desired softness; (5) desired scent or aroma; and(6) the ability to be manufactured in a cost-effective manner. Thepresent invention is also directed to methods of making abrasive websand nonwoven composite materials and various uses for the abrasive websand nonwoven composite materials.

[0022] The abrasive webs and nonwoven composite materials of the presentinvention comprise a variety of materials, which provide one or more ofthe above-mentioned desired properties. A description of suitablematerials for forming the abrasive webs and nonwoven composite materialsof the present invention is given below.

[0023] I. Abrasive Webs and Nonwoven Composite Components

[0024] The abrasive webs and nonwoven composite materials of the presentinvention may comprise one or more layers of material, wherein eachlayer contributes at least one desired property to the resultingabrasive web or nonwoven composite material. Suitable layers and layercomponents for forming the abrasive webs and nonwoven compositematerials of the present invention are described below.

[0025] A. An Abrasive Layer of Meltblown Fibers

[0026] The abrasive webs and nonwoven composite materials of the presentinvention desirably comprise at least one abrasive layer of meltblownfibers. In one exemplary embodiment of the present invention, theabrasive web comprises a single layer of meltblown fibers. The layer ofmeltblown fibers is a nonwoven fabric. In other words, the single layerof meltblown fibers possesses enough structural integrity to form anonwoven fabric, which may exist as a nonwoven fabric without the needfor a supporting substrate. The meltblown fibers may be (1) autogenouslybonded to one another, (2) bonded to one another using an externalsource of heat and/or pressure, or (3) both (1) and (2). As used herein,the term “autogenously bonded” is used to describe fibers, which bond toone another as the fibers come into contact with one another afterleaving an extrusion die.

[0027] The fibers of the abrasive meltblown fabric layer may be madefrom a variety of materials depending on a number of factors including,but not limited to, processability of the fiber-forming material,desired properties of the individual web and the resulting compositematerial, and manufacturing costs. Suitable fiber-forming materialsinclude, but are not limited to, polypropylene, polybutylene,polyethylene terephthalate, polyamide, and combinations thereof.Desirably, the fibers of the abrasive meltblown fabric layer comprisepolypropylene. Commercially available polypropylenes suitable for use inthe present invention include, but are not limited to, polypropyleneavailable from Basell Polyolefins (Wilmington, Del.) under the tradedesignation Basell. In one desired embodiment of the present invention,the fibers of the abrasive meltblown fabric layer comprise polypropylenefibers formed from polypropylene available from Basell Polyolefins(Wilmington, Del.) under the trade designation Basell, and having a meltflow index of about 800 g/10 min as measured according to ASTM D-1238.

[0028] Desirably, the fibers of the abrasive meltblown fabric layer havean average fiber diameter of less than about 100 microns. Moredesirably, the fibers have an average fiber diameter of from about 0.5micron to about 40 microns. Even more desirably, the fibers have anaverage fiber diameter of from about 10 micron to about 35 microns.

[0029] The abrasive meltblown fabric layer may have a basis weight,which varies depending upon the particular end use of the individual weband the resulting composite material. Desirably, the abrasive meltblownfabric layer has a basis weight of less than about 500 grams per squaremeter (gsm) prior to stretching. More desirably, the abrasive meltblownfabric layer has a basis weight of from about 2.5 gsm to about 500 gsmprior to stretching. Even more desirably, the abrasive meltblown fabriclayer has a basis weight of from about 8 gsm to about 100 gsm prior tostretching, even more desirably from about 28 gsm to about 60 gsm priorto stretching.

[0030] As with the basis weight, the abrasive meltblown web may have athickness, which varies depending upon the particular end use of theindividual web and the resulting composite material. Desirably, theabrasive meltblown web has a thickness of less than about 1000 microns(μm) prior to stretching. More desirably, the abrasive meltblown web hasa thickness of from about 10 μm to about 500 μm prior to stretching.Even more desirably, the abrasive meltblown web has a thickness of fromabout 20 μm to about 100 μm prior to stretching.

[0031] In most embodiments, the fibers within the abrasive meltblown webare uniformly distributed within the web. However, there may be someembodiments wherein it is desirable to have a non-uniform distributionof fibers within the abrasive meltblown web.

[0032] B. Absorbent Layer of Nonwoven Fibers

[0033] The composite materials of the present invention may furthercomprise an absorbent layer in the form of an additional nonwovenfabric. Suitable nonwoven fabric layers include, but are not limited to,a meltblown fabric layer, a spunbonded fabric layer, a spunlaced fabriclayer, a carded thermally-bonded (or ‘point-bonded’) nonwoven containinga percentage of viscose fibers or other hydrophilic fiber, or acombination thereof. Desirably, the absorbent layer comprises ameltblown fabric layer or a spunbonded fabric layer.

[0034] The fibers of the absorbent nonwoven fabric layer may be madefrom a variety of materials depending on a number of factors including,but not limited to, processability of the fiber-forming material,desired properties of the individual web and the resulting compositematerial, and manufacturing costs. Desirably, the fibers of theabsorbent nonwoven fabric layer any of the above-mentioned fiber-formingmaterials.

[0035] When the absorbent layer comprises a meltblown fabric layer, thefibers of the absorbent meltblown fabric layer desirably have an averagefiber diameter of less than about 100 microns. More desirably, thefibers of the absorbent meltblown fabric layer have an average fiberdiameter of from about 0.5 micron to about 40 microns. Even moredesirably, the fibers have an average fiber diameter of from about 1micron to about 30 microns.

[0036] Further, when the absorbent layer comprises a meltblown fabriclayer, the meltblown fabric layer desirably has a basis weight of lessthan about 1000 grams per square meter (gsm) prior to stretching. Moredesirably, the absorbent meltblown fabric layer has a basis weight offrom about 25 gsm to about 500 gsm prior to stretching. Even moredesirably, the absorbent meltblown fabric layer has a basis weight offrom about 30 gsm to about 100 gsm prior to stretching.

[0037] As with the basis weight, the absorbent meltblown fabric layermay have a thickness, which varies depending upon the particular end useof the composite material. Desirably, the absorbent meltblown fabriclayer has a thickness of less than about 1000 microns (μm) prior tostretching. More desirably, the absorbent meltblown fabric layer has athickness of from about 10 μm to about 500 μm prior to stretching. Evenmore desirably, the absorbent meltblown fabric layer has a thickness offrom about 20 μm to about 100 μm prior to stretching.

[0038] As discussed above, the absorbent nonwoven fabric layer maycomprise nonwoven fabric layers other than a meltblown fabric layer. Inone desired embodiment, the absorbent nonwoven fabric layer comprises aspunbonded fabric layer having fiber dimensions, fabric basis weight,and fabric thickness values similar to the values given above withregard to the absorbent meltblown fabric layer.

[0039] C. Absorbent Layer of Woven Fibers

[0040] In addition to or as an alternative to the absorbent nonwovenlayer, the composite materials of the present invention may comprise anabsorbent layer in the form of a woven fabric. Suitable woven fabriclayers include, but are not limited to, woven fabrics formed fromabsorbent fibers, hydrophilic fibers, or a combination thereof. Thefibers of the absorbent woven fabric layer may be made from any of theabove-described materials. Further, the absorbent woven fabric layer mayinclude cellulosic fibers, cotton fibers, viscose fibers, or any otherabsorbent or hydrophilic fiber.

[0041] Further, when the absorbent layer comprises a woven fabric layer,the woven fabric layer desirably has a basis weight of less than about1000 grams per square meter (gsm) prior to stretching. More desirably,the absorbent woven fabric layer has a basis weight of from about 25 gsmto about 500 gsm prior to stretching. Even more desirably, the absorbentwoven fabric layer has a basis weight of from about 30 gsm to about 100gsm prior to stretching.

[0042] As with the basis weight, the absorbent woven fabric layer mayhave a thickness, which varies depending upon the particular end use ofthe composite material. Desirably, the absorbent woven fabric layer hasa thickness of less than about 1000 microns (μm) prior to stretching.More desirably, the absorbent woven fabric layer has a thickness of fromabout 10 μm to about 500 μm prior to stretching. Even more desirably,the absorbent woven fabric layer has a thickness of from about 20 μm toabout 100 μm prior to stretching.

[0043] D. Additives

[0044] In addition to the fiber-forming materials mentioned above,various additives may be added to the fiber melt and extruded toincorporate the additive into the fiber. Alternatively, one or moreadditives may be coated onto the fiber during or after the fabricforming process. Suitable additives include, but are not limited to,fillers, stabilizers, plasticizers, tackifiers, flow control agents,cure rate retarders, adhesion promoters (for example, silanes andtitanates), adjuvants, impact modifiers, expandable microspheres,thermally conductive particles, electrically conductive particles, andthe like, such as silica, glass, clay, talc, pigments, colorants,scent-producing agents, surfactants, detergents, glass beads or bubbles,antioxidants, optical brighteners; antimicrobial agents; surfactants;fire retardants; and fluoropolymers. Typically, the amount of one ormore additives is less than about 25 weight percent, desirably, up toabout 2.5 percent, based on the total weight of the fiber and/or fabric.

[0045] One or more of the above-described additives may be used toreduce the weight and/or cost of the resulting fiber and/or web, adjustviscosity, or modify the thermal properties of the fiber or confer arange of physical properties derived from the physical property activityof the additive including: cleansing properties,antimicrobialproperties, scent-producing properties, color-producing properties, etc.

[0046] In one desired embodiment of the present invention, at least onecolorant and at least one scent-producing additive are added to orcoated onto the fiber-forming materials of the abrasive meltblown layerand/or the at least one additional fabric layer. In one exemplaryembodiment, the fiber-forming materials of the abrasive meltblown layerare substantially free of colorants and scent-producing additives, whilethe fiber-forming materials of the at least one additional fabric layercontains at least one colorant and at least one scent-producingadditive. In another exemplary embodiment, the fiber-forming materialsof the abrasive meltblown layer contain at least one colorant and/or atleast one scent-producing additive, while the fiber-forming materials ofthe at least one additional fabric layer are substantially free ofcolorants and scent-producing additives. Desirably, the colorant, whenpresent, comprises a pigment or dye providing a desired color, such asyellow, orange, or any other desired color. Desirably, thescent-producing additive, when present, provides a desired scent, suchas a lemon scent, a pine scent, or any other desired scent. One exampleof a suitable scent-producing additive is Lemon Citrus #50-3264commercially available from Cognis Corporation (Ambler, Pa.).

[0047] In a further desired embodiment of the present invention, atleast one layer of the composite material comprises a soap, surfactantor detergent. The terms “soap”, “surfactant” and “detergent” are usedherein to describe materials for cleaning a surface, such as cookware,utensils, countertop, or any other surface. For example, a surfactantmay be added to the fiber-forming material of the abrasive layer and/orthe additional fabric layer before the abrasive layer and/or theadditional fabric layer is formed to make the abrasive layer and/or theadditional fabric layer more hydrophilic. Alternatively or additionally,a surfactant may be applied to the fiber-forming materials of theabrasive layer and/or the additional fabric layer after the abrasivelayer and/or the additional fabric layer is formed. In addition to asurfactant, one or more antimicrobial agents, such as silver zeolite,may also be incorporated into the abrasive layer and/or the additionalfabric layer.

[0048] A variety of hydrophilic additives, soaps, surfactants anddetergents may be used in the present invention. Suitable surfactantsinclude, but are not limited to, nonionic surfactants, anionicsurfactants, and a combination thereof. One example of a suitablehydrophilic additive is polyethylene glycol. One example of a suitabledetergent is Detergent 0240-82 commercially available from CognisCorporation (Ambler, Pa.).

[0049] II. Methods of Making Bonded Composites

[0050] The composite components described above may be used to prepare abonded composite, which may be used as a precursor to the stretchedcomposite materials of the present invention. Exemplary compositematerial components are shown in FIG. 1. As shown in FIG. 1, exemplarycomposite material 10 comprises an abrasive web 11 including extrudedpolypropylene fibers 15 and an additional nonwoven material 12comprising extruded polypropylene fibers 16.

[0051] An exemplary bonded composite is shown in FIG. 2. The exemplarybonded composite 10 of FIG. 2 comprises upper layer 11 bonded to lowerlayer 12. For example, upper layer 11 may be an abrasive meltblownnonwoven fabric of polypropylene fibers, and lower layer 12 may be asecond meltblown nonwoven fabric of polypropylene fibers. Although upperlayer 11 may be bonded to lower layer 12 using a variety of bondingprocesses as described below, exemplary bonded composite 10 of FIG. 2comprises point bonds 13 uniformly distributed along an upper surface110 of upper layer 11.

[0052]FIG. 3 depicts a cross-sectional view of exemplary bondedcomposite 10 of FIG. 2 along line A-A. As shown in FIG. 3, bondedcomposite 10 has an overall thickness, which is the combined thicknessof upper layer 11 and lower layer 12. As used herein, the term “overallthickness” when used to describe the thickness of bonded composite 10describes the average thickness of the bonded composite 10 in areasother than point-bonded areas 13. Typically, bonded composite 10 has anoverall thickness of from about 40 microns (μm) to about 250 μm prior tostretching. Desirably, bonded composite 10 has an overall thickness offrom about 60 μm to about 110 μm prior to stretching.

[0053] The bonded composite may be prepared in a number of ways. Oneexemplary method of making a meltblown web for use in the bondedcomposite is depicted in FIG. 4.

[0054] As shown in FIG. 4, molten polymer 300 is introduced into a dieassembly 320. Die assembly 320 comprises a plurality of spinnerets (notshown) from which molten polymer 300 is extruded. Molten polymer 300exits die assembly 320 at location 325 and enters into a curtain ofprocess air 330. The curtain of process air 330 attenuates extrudedpolymer fibers 350 as the fibers 350 travel a distance d from an exit ofthe plurality of spinnerets (not shown) to a collection surface atlocation 360 on an outer surface of drum 365. Drum 365 rotates at adesired speed to form a meltblown web 370, which moves along an outersurface of drum 365. Meltblown web 370 moves along drum 365 to point366, wherein a nip roll 367 contacts the meltblown web 370 and guidesthe web off of drum 365 onto an outer surface of nip roll 367. Meltblownweb 370 may proceed onto other processes along the process line, such asa calender assembly 380.

[0055] Calender assembly 380 comprises a first roll 381 and a secondroll 382 which nip the meltblown web 370 to further bond the fibers ofthe web to one another. First roll 381 and second roll 382 may have asmooth surface to form bonding sites throughoutmeltblown web 370.Alternatively, at least one of first roll 381 and second roll 382 hasraised portions along the roll surface, which results in a point-bondingpattern across meltblown web 370 (such as the point-bonding shown inFIGS. 2-3). Each point of the point-bonding pattern may have any shapeand size desired. The total bonded area of the meltblown web 370 mayvary from about 5 to about 95 percent of the total surface area of theweb, desirably, from about 8 to about 50 percent of the total surfacearea of the web, more desirably, from about 25 to about 40 percent ofthe total surface area of the web.

[0056] The resulting meltblown web 370 may be taken off the process linein the form of a roll, such as on a cardboard or plastic tube, andstored for later processing. Alternatively, resulting meltblown web370may be further processed by joining meltblown web 370 to anothercomposite component layer, such as an additional nonwoven fabric layer,and then processed through a bonding process, such as theabove-described calendering process.

[0057] Desirably, an additional composite component layer, such as anadditional nonwoven fabric layer, is joined to meltdown web 370 as shownin FIG. 5. As meltblown web 370 (also referred to as meltblown layer 12)leaves nip roll 367 and proceeds toward calender assembly 380, meltblownweb 370 is brought into contact with a pre-manufactured abrasivemeltblown fabric layer 11. The combined meltblown web 370/abrasivemeltblown fabric layer 11 assembly proceeds through calender assembly380 to produce bonded composite material 10. It should be noted that thepre-manufactured abrasive meltblown fabric layer 11 may be preparedusing a process as shown in FIG. 4. Further, it should be noted that awoven fabric (not shown) may be joined to a pre-manufactured abrasivemeltblown fabric layer 11 and processed through calender assembly 380 toproduce a bonded composite material.

[0058] When a point-bonding process is used to join the meltblown web370 (or a woven fabric) to an additional nonwoven fabric layer, it isdesirable for the bonded pre-stretched composite material to have a bondcover area of less than about 50% based on a total surface area of thebonded pre-stretched composite material. More desirably, the bondedpre-stretched composite material has a bond cover area of from about 30%to about 40% based on a total surface area of the bonded pre-stretchedcomposite material.

[0059] One alternative method of forming a bonded composite material 10is shown in FIG. 6. As the fibers 350 travel a distance d from an exitof the plurality of spinnerets (not shown) to the collection surface atlocation 360 on an outer surface of drum 365, a second substrate 12(e.g., a pre-manufactured absorbent nonwoven or woven fabric layer) isbrought into contact with the plurality of fibers 350. Second substrate12 can be stored in roll form 340. In calender assembly 380, first roll381 and second roll 382 bond the fibers of meltblown web 370 to oneanother and also bond meltblown web 370 to second substrate 12 to formbonded pre-stretched composite material 10. The degree of bonding withinmeltblown web 370 and to second substrate 12 may vary as describedabove.

[0060] Typically, the method of forming the meltblown web involves meltextruding a thermoformable material at a melt extrusion temperature offrom about 130° C. to about 350° C. In particular, for polypropylenefibers, the polypropylene is melt extruded at a melt extrusiontemperature of about 270° C.

[0061] The die assembly comprises a plurality of spinnerets throughwhich molten thermoformable material is extruded. Desirably, the dieassembly comprises a plurality of spinnerets, wherein the number ofspinneret holes through the die is at least 700 spinneret holes perlinear meter. Typically, the plurality of spinnerets has an average holediameter of from about 0.25 to about 0.75 mm.

[0062] Desirably, the method of making the meltblown web comprises meltextruding a thermoformable material, such as polypropylene, at a rate ofat least 25 kilograms per hour per linear meter of extrusion width(k/hr/lm). In one embodiment, the weight of extruded polymer per orificeof die is from about 0.3 g of polymer per hole per minute to about 2.0 gof polymer per hole per minute.

[0063] Desirably, the method of making the meltblown web comprises usinga stream of air to attenuate the plurality of extruded fibers at a pointbelow an exit of the plurality of spinnerets within the die assembly.The exit of the plurality of spinnerets may be positioned a distance, d,above the collection surface. In one embodiment of the presentinvention, the distance, d, may be adjusted by moving the plurality ofspinnerets up or down relative to the collection surface. This may bebeneficial for control of fiber size, web pore size, fiber fusion, andweb basis weight uniformity. Desirably, distanced, may vary from about100 mm to about 1500 mm.

[0064] The stream of air used to attenuate the plurality of extrudedfibers desirably has an air speed of from about 5 meters per second(ms⁻¹) to about 300 ms⁻¹. The air stream volume typically ranges fromabout 550 cm³/sec per centimeter (cm) of die width (3 cfm per inch ofdie width) to about 1860 cm³/sec per centimeter (cm) of die width (10cfm per inch of die width), desirably about 1100 cm³/sec per centimeter(cm) of die width (6 cfm per inch of die width). Further, the stream ofair desirably has an air temperature of from about 150° C. to about 400°C., more desirably, from about 160° C. to about 240° C., and even moredesirably about 200° C.

[0065] In one embodiment of the present invention, the method uses a dieassembly comprising a plurality of spinnerets wherein the plurality ofspinnerets are arranged along a die having a length,l, and a width, w,with an upper surface (i.e., die entrance), a lower surface (i.e., dieexit), two side surfaces, and two end surfaces. Typically, the dieassembly has a length, 1, of from about 0.05 meters (m) to about 3 mextending in a first direction perpendicular to the web (i.e., the crossdirection of the web); and a width, w, of from about 1 mm to about 100mm extending in a second direction parallel to the web (i.e., themachine direction of the web). A plurality of spinneret holes extends ina direction from the upper surface to the lower surface. A stream ofattenuating air may contact the plurality of fibers at a point below anexit of the plurality of spinnerets, wherein the stream of air flowsthrough slots positioned along the two side surfaces (see FIGS. 4-6).

[0066] It should be noted that the collection surface may be in the formof a flat surface as oppose to a rotating drum (as shown in FIGS. 4-6).The collection surface may comprise a drum supporting a carriermaterial; an endless belt, a horizontal table; a horizontal tablesupporting a carrier material; or a tenter frame supporting a carriermaterial.

[0067] Desirably, the collection surface is a drum having a diameter offrom about 0.3 m to about 2.0 m, and a width of from about 0.05 m toabout 3 m. The drum may have an outer surface comprising a smooth metalsurface or a wire screen mesh. Desirably, the drum has an outer surfacecomprising a wire screen mesh.

[0068] The drum outer surface may be of any appropriate material, suchas metal, polyester or teflon. In one desired embodiment, the drum outersurface is a wire screen mesh having an x-y matrix pattern with gaps inbetween the wire mesh material. Any gauge wire mesh material may be usedas long as the meltblown web that is formed on the wire mesh materialmaintains a sufficient amount of integrity and strength after beingremoved from the wire mesh material.

[0069] The speed of the drum may vary depending on the throughput of theprocess line. Desirably, an outer surface of the drum has a linear speedof from about 0.1 μm/min to about 150 m/min.

[0070] The method of forming the bonded pre-stretched composite mayinclude any of the above-described features. In addition, the method offorming the bonded pre-stretched composite may include one or more ofthe following process steps:

[0071] (1) rotating the drum to advance the meltblown web along an outersurface of the drum;

[0072] (2) nipping the meltblown web between a nip roll and the drum,wherein the web separates from the drum at a nip point and follows a webpath along an outer surface of the nip roll;

[0073] (3) coating the bonded pre-stretched composite with a surfacetreatment;

[0074] (4) attaching the bonded pre-stretched composite to a cardboardor plastic tube;

[0075] (5) taking-up the bonded pre-stretched composite in the form of aroll; and

[0076] (6) slitting the bonded pre-stretched composite to form two ormore slit rolls.

[0077] III. Methods of Making Stretched Composite Materials

[0078] The bonded composite may be further processed through astretching apparatus, such as the exemplary stretching apparatus shownin FIG. 7A. As shown in FIG. 7A, bonded composite 10 proceeds throughstretching apparatus 60 and exits as stretched composite material 395.Stretching apparatus 60 comprises two interengaged drums, upper drum 61and lower drum 62, and a nip roller 63. Each drum consists ofalternating discs having different disc diameters. A cross-sectionalview of upper drum 61 and lower drum 62 is given in FIG. 7B.

[0079] As shown in FIG. 7B, upper drum 61 consists of alternating discs612 and 613 having a larger disc diameter, d₆₁₂, and a smaller diameter,d₆₁₃, respectively. Lower drum 62 also consists of alternating discs 615and 616 having a larger disc diameter, d₆₁₅, and a smaller diameter,d₆₁₆, respectively. As bonded composite 10 approaches stretchingapparatus 60, tension is exerted on bonded composite 10 by nip roller 63to keep bonded composite 10 positioned next to lower drum 62. As bondedcomposite 10 proceeds through stretching apparatus 60, a stretchingforce is exerted on bonded compositelo so as to stretch bonded composite10 in specific areas referred to herein as “microstretched portions.”The microstretched portions extend in the machine direction of thestretched composite material 395, and are located substantially betweenadjacent peaks and valleys as described below.

[0080] As shown in FIG. 7B, discs 612 on upper drum 61 exert astretching force on bonded composite 10, forcing portions of bondedcomposite 10 into the gaps between discs 615 on lower drum 62. Peaks 82and valleys 84 are formed in bonded composite 10. The areas betweenpeaks 82 and valleys 84 are microstretched portions 86. It is believedthat a substantial amount of the total stretching of bonded composite 10occurs in microstretched portions 86. The distance between peaks 82 andvalleys 84 (and the length of microstretched portions 86 as measured inthe cross direction of bonded compositely) may vary depending on thewidth and diameters of discs612, 613, 615 and 616. Further, it isbelieved that peaks 82 and valleys 84 have a higher concentration ofbonds between the composite material layers (e.g., upper layer 11 andlower layer 12) compared to a bond concentration in the microstretchedportions 86.

[0081] Typically, discs 612, 613, 615 and 616 have a width ranging fromabout 0.5 mm (20 mil.) to about 3.0 mm (120 mil.), desirably, from about1.0 mm (40 mil.) to about 1.5 mm (60 mil.). In one exemplary embodimentof the present invention, discs 612, 613, 615 and 616 have the followingwidths: disc 612-1.27 mm (50 mil.); disc 613-2.54 mm (100 mil.); disc615-1.27 mm (50 mil.); and disc 616-2.54 mm (100 mil.).

[0082] Typically, discs 612, 613, 615 and 616 have a diameter rangingfrom about 5.1 cm (2 inches (in.)) to about 61.0 cm (24 in.), desirably,from about 7.6 cm (3 in.) to about 30.5 cm (12 in.). In one exemplaryembodiment of the present invention, discs612, 613, 615 and 616 have thefollowing diameters: disc 612-17.8 cm (7 in.); disc 613-15.2 cm (6 in.);disc 615-17.8 cm (7 in.); and disc 616-15.2 cm (6 in.).

[0083] One suitable stretching apparatus for stretching the bondedpre-stretched composite is disclosed in U.S. Pat. No. 4,368,565 assignedto Biax-Fiberfilm Corporation (Neenah, Wis.), the entire content ofwhich is hereby incorporated by reference.

[0084] The bonded composite may be laterally stretched using theabove-describe stretching apparatus to increase the width of the bondedcomposite up to about 30% (i.e., the final width is 1.3 times theoriginal width). Desirably, the bonded composite is laterally stretchedto a final width, which is from about 2% to about 25% greater than theoriginal width of the bonded pre-stretched composite, more desirably,from about 10% to about 25% greater than the original width of thebonded pre-stretched composite.

[0085] It should be noted that any single layer of the compositematerial of the present invention may be laterally stretched using theabove-describe stretching apparatus prior to being joined to one or moreother layers of the composite material. For example, an absorbent layermay be stretched to increase the width of the absorbent layer up toabout 30% (i.e., the final width is 1.3 times the original width) priorto joining the absorbent layer to an abrasive nonwoven layer. Typically,prior to being stretched, the absorbent layer is calendered as describedabove, although calendering is an optional step. After stretching theabsorbent layer, the stretched absorbent layer may be joined to theabrasive nonwoven layer to form the composite material. The resultingcomposite material may be further processed as described below.

[0086] In one desired embodiment of the present invention, the compositematerial comprises (i) a calendered, stretched absorbent layercomprising a meltblown or spunbonded nonwoven fabric, and (ii) anabrasive nonwoven fabric layer bonded to the stretched absorbent layer.In this embodiment, the absorbent layer is desirably laterally stretchedto a final width, which is from about 2% to about 25% greater than theoriginal width of the absorbent layer, more desirably, from about 10% toabout 25% greater than the original width of the absorbent layer. Theabrasive layer may be either (i) point-bonded to the stretched absorbentlayer at a desired bond cover area of from about 30% to about 40% basedon a total surface area of the bonded composite material, or (ii)overblown onto the stretched absorbent layer (using the meltblowingprocess described above and depicted in FIG. 6) to produce a compositematerial. Desirably, the abrasive layer is overblown onto the stretchedabsorbent layer to produce a composite material.

[0087] IV. Methods of Making Composite Materials Containing One or MoreAdditives

[0088] As described above, one or more additives may be incorporatedinto one or more layers of the composite material of the presentinvention. The one or more additives may be incorporated into anindividual layer of the composite material prior to being bonded to oneor more additional layers of the composite material. Alternatively, oneor more additives may be incorporated into each of the individual layersof the composite material after being bonded to one another.

[0089] In one embodiment of the present invention, one or moreadditives, such as a colorant, a scent-producing agent, and/or asurfactant, are sprayed onto the fibers as the fibers travel distanced,between (i) the exit of the plurality of spinnerets and (ii) thecollection surface (see FIGS. 4-6). In an alternative embodiment, one ormore additives, such as a colorant, a scent-producing agent, and/or asurfactant, are coated onto and/or impregnated into the compositematerial. The coating process may be any known coating process, such asa spray coating, pad coating, dip coating, etc. One method ofimpregnating one or more additives into the composite material is via anextrusion process, wherein the composite material is passed through anextrusion die having a width and height similar to or slightly largerthan the dimensions of the composite material. In this embodiment, oneor more additives are fed into the extruder as the composite materialtravels through the extruder, resulting in an impregnation of thecomposite material.

[0090] In a further embodiment of the present invention, one or moreadditives may be incorporated into the polymer melt prior to fiberformation. In this embodiment, the one or more additives are typicallyin the form of finely divided solid particles, which may be blended withthe polymer. The particle size is small relative to the die orificesused to extrude the fiber-forming material.

[0091] V. Stretched Composite Materials

[0092] The stretched composite materials of the present invention mayhave a cross-sectional configuration along a cross direction of thecomposite, which varies depending on the stretching apparatus used. Asused herein, the term “stretched composite materials” refers tocomposite materials of the present invention wherein (i) the entirecomposite material is stretched or (ii) at least one layer of thecomposite material (e.g., the absorbent layer) is stretched using themethod as described above. In one exemplary embodiment of the presentinvention, the stretched composite material has a wave-likecross-sectional configuration along a cross direction of the stretchedcomposite material, wherein the wave-like cross-sectional configurationcontains a plurality of alternating peaks and valleys. Exemplarywave-like cross-sectional configurations are shown in FIGS. 8A and 8B.

[0093] As shown in FIGS. 8A and 8B, stretched composite material 395 mayhave a sine-wave shape (FIG. 8A) or a truncated cone-wave shape (FIG.8B). It should be noted that stretched composite material 395 may haveother cross-sectional configurations depending on the shape anddimensions of the alternating discs used to stretch the compositematerial. In FIGS. 8A and 8B, stretched composite material 395 has peaks82, valleys 84, and microstretched portions 86 positioned between peaks82 and valleys 84. In a desired embodiment of the present invention, themicrostretched portions86 extend in the machine direction of stretchedcomposite material 395, and are located substantially between adjacentpeaks 82 and valleys 84.

[0094] As shown in FIG. 8B, stretched composite material 395 may have across-sectional configuration, wherein each peak82 is separated fromadjacent peaks as viewed along the cross direction of stretchedcomposite material 395 and located substantially within a first plane.Likewise, each valley 84 may be separated from adjacent valleys asviewed along the cross direction of stretched composite material395 andlocated substantially within a second plane parallel with and below thefirst plane. The microstretched portions86 are located substantiallybetween the first plane and the second plane. In one embodiment of thepresent invention, stretched composite material 395 have across-sectional configuration, wherein the average distance betweenadjacent peaks ranges from about 1.0 mm to about 10.0 mm, and theaverage distance between adjacent valleys ranges from about 1.0 mm toabout 10.0 mm. As used herein, the term “distance between adjacentpeaks” refers to the distance between the apex of one peak and the apexof an adjacent peak. Desirably, the average distance between adjacentpeaks ranges from about 2.0 mm to about 6.0 mm, and the average distancebetween adjacent valleys also ranges from about 2.0 mm to about 6.0 mm.

[0095] In a further embodiment of the present invention, stretchedcomposite material 395 has a cross-sectional configuration, wherein themicrostretched portions 86 have an average width as measured along thecross direction of stretched composite material 395 between the firstplane and the second plane ranging from about 0.05 mm to about 8.0 mm,more desirably, from about 1.0 mm to about 3.0 mm.

[0096] It should be understood that when the stretched compositematerial of the present invention comprises a stretched layer (e.g., astretched absorbent layer) and an unstretched layer (e.g., an abrasivenonwoven layer), the composite material may still have any of theabove-described cross-sectional configurations having peaks and valleysas described above. However, the above-described microstretched portionswill only be present within the stretched layer of the compositematerial.

[0097] As discussed above, the stretched composite materials of thepresent invention may have a final width of at least 2% greater than thebonded pre-stretched composite. Further, the stretched compositematerials of the present invention (or a stretched layer thereof) mayhave a final thickness of at least 20% greater than the pre-stretchedcomposite material (or pre-stretched layer). Desirably, the stretchedcomposite material (or a stretched layer thereof) has a final thicknessof from about 30% to about 60% greater than the pre-stretched compositematerial (or pre-stretched layer), more desirably, from about 35% toabout 50% greater than the pre-stretched composite material (orpre-stretched layer).

[0098] Desirably, the stretched composite material (or a stretched layerof the composite material) has the following properties:

[0099] (1) an overall thickness at least 40% greater than apre-stretched thickness of the composite material (or composite layer);

[0100] (2) an absorbency of at least 20% greater than the pre-stretchedabsorbency of the composite material (or composite layer).

[0101] VI. Uses For Stretched and Pre-Stretched Composite Materials

[0102] The stretched and pre-stretched composite materials of thepresent invention may be used in a variety of applications includingresidential, commercial (e.g., food service businesses), and industrialapplications. The stretched and pre-stretched composite materials of thepresent invention are particularly useful as materials for formingwipes. The wipes may be used for cleaning pots and pans, as well as,surface cleaning for bathrooms, outdoor camping, recreational vehicles,etc. The wipes may also be cut to a suitable dimension for use in guncleaning applications.

[0103] In one exemplary embodiment of the present invention, thestretched composite material is formed into a wipe. The wipe comprisesan outer layer of an abrasive meltblown nonwoven fabric and at least oneabsorbent nonwoven fabric bonded to the abrasive meltblown nonwovenfabric. The wipe may have any desired size and shape. Typically, thewipes are available as separate individual sheets or as connectedindividual sheets in roll form, similar to a roll of paper towels,wherein the individual sheets have a width and/or length of up to about50 cm. In one exemplary roll of wipes, each individual wipe has a widthof about 28 cm and a length of about 22 cm.

[0104] Desirably, the wipe comprises (a) an abrasive meltblown nonwovenfabric formed from polypropylene fibers having an average fiber diameterof less than about 100 microns and a fabric basis weight of from about28 gsm to about 60 gsm; and (b) at least one additional meltblownnonwoven fabric formed from polypropylene fibers having an average fiberdiameter of less than about 100 microns and a fabric basis weight offrom about 44 gsm to about 100 gsm. In one desired embodiment, the wipecomprises (a) an abrasive meltblown fabric layer of extrudedpolypropylene fibers having a basis weight of about 34 gsm and anaverage fiber diameter ranging from about 10 μm to about 32 μmcalendared to (b) an absorbent meltblown nonwoven fabric of extrudedpolypropylene fibers having an average fiber diameter of from about 2 μmto about 10 μm.

[0105] The wipe material is desirably calendered at a point-bondingdensity of about 33% (i.e., about 33% of the total surface area of anouter layer of the composite wipe material is bonded) to form pocketswithin the layers of the composite material (i.e., point bonds 13 asshown in FIG. 2). The pockets allow the composite wipe material tocollect dirt or other particles from a surface being wiped. As anabrasive force is applied to the surface, dirt or other particles arereleased from the surface. The capture of particles in the wipe pocketsallows the particles to move away from the surface, which reducesscratching or damaging of the surface being wiped. Furthermore, it isbelieved that the pockets increase the durability and life-span of thecomposite wipe material.

[0106] The above-described calendering step results in a plurality ofpockets uniformly distributed over the composite or wipe material,wherein each pocket desirably has a pocket lip and a pocket floor (seeFIG. 3, which depicts pocket lip 131 and pocket floor 132). The pocketlips are desirably positioned along an outer surface of the abrasivelayer while the pocket floors are positioned within an interior of thecomposite material, desirably within the additional nonwoven fabriclayer. The plurality of pockets may be uniformly distributed in anamount depending on the size and shape of the pockets. In one exemplaryembodiment, the plurality of pockets are uniformly distributed in anamount of about 25 pockets per square centimeter of outer surface of theabrasive layer, wherein each pocket has a substantially square ordiamond shape having a pocket surface area of about 1 square millimeter.However, it should be understood that the size, shape, and number ofpockets per given area of composite material may vary as desired.

[0107] Desirably, the wipe comprises at least one of (i) a colorant,(ii) a scent-producing additive, (iii) a surfactant, and (iv) anantimicrobial agent in (a) the abrasive layer, (b) the absorbentnonwoven and/or woven layer, or both. In one desired embodiment, thewipe comprises a colorant (e.g., yellow) in the abrasive layer, and botha scent-producing additive (e.g., lemon scent) and a surfactant in theabsorbent meltblown nonwoven layer. In a further desired embodiment, thewipe comprises an abrasive layer substantially free of additives, and anabsorbent meltblown nonwoven layer comprising a colorant (e.g., yellow),a scent-producing additive (e.g., lemon scent), and a surfactant.

[0108] The wipe may be used in residential, commercial, or industrialapplications. The presence of a surfactant impregnated into the wipeenables the wipe to produce a cleaning foam composition once the wipe isexposed to water. The wipe provides an abrasive cleaning surface andsurfactant composition, which is safe to use on teflon-coated cookware,as well as, other scratch-sensitive surfaces, such as porcelain surfacesand painted surfaces.

[0109] In a further exemplary embodiment of the present invention, thepre-stretched composite material (i.e., no layers in the compositematerial are stretched) is formed into a wipe. The wipe comprises anouter layer of an abrasive meltblown nonwoven fabric and at least oneabsorbent nonwoven fabric bonded to the abrasive meltblown nonwovenfabric. As with the stretched composite wipe described above, thepre-stretched composite wipe may have any desired size and shape, andmay be available as separate individual sheets or as connectedindividual sheets in roll form, similar to a roll of paper towels. Inone exemplary embodiment, the pre-stretched composite wipes areavailable as separate individual sheets, wherein each individual wipehas a width of about 33 cm and a length of about 29.7 cm.

[0110] The present invention is described above and further illustratedbelow by way of examples, which are not to be construed in any way asimposing limitations upon the scope of the invention. On the contrary,it is to be clearly understood that resort may be had to various otherembodiments, modifications, and equivalents thereof which, after readingthe description herein, may suggest themselves to those skilled in theart without departing from the spirit of the present invention and/orthe scope of the appended claims.

TEST METHODS

[0111] The following test methods were used to evaluate compositematerials of the present invention.

[0112] Softness Testing:

[0113] Softness is determined using a drapeability test. Samples offabric are cut into 2.54 cm (1 in.)×12.7 cm (5 in.) strips. Samples aretaped to the edge of a flat, level surface so that the sample hangs overthe edge of the surface. The distance from the surface to the hangingedge of the strip is measured. A longer distance measurement indicates asofter and more drapeable fabric sample.

[0114] Absorbency Testing.

[0115] Samples are cut into 12.7 cm (5 in.) diameter circles. The drysamples are weighed. The dry weight is recorded. The samples areimmersed in a water bath for 10 minutes. Samples are then allowed todrain on a rack for 10 minutes. The wet samples are weighed. The wetweight is recorded. The absorbency is expressed in percentage dryweight.

[0116] Resistance to Water Penetration Testing:

[0117] The hydrohead test method measures the resistance of a fabric tothe penetration of water under low hydrostatic pressure. The method isperformed by applying a fabric sample to the top of a test headreservoir. Water pressure is increased at a constant rate until waterleaks through the fabric sample. The water pressure is read at the firstsign of leakage in three separate areas of the sample. Water pressure isreported in units of psi or mbar. Details of this test method aredescribed in INDA test method, IST 80.6 (01)-Standard Test Method forWater Resistance, The Hydrostatic Pressure Test.

EXAMPLE 1 Preparation of an Abrasive Meltblown Web

[0118] A fiber-producing melt was prepared by melting a fibercomposition comprising polypropylene at a melt temperature of about 270°C. The polymer melt was extruded a rate of 100 kilograms per hour perlinear meter of extrusion width (kg/hr/lm) using an apparatus similar tothe apparatus as shown in FIG. 4. The molten polymer was introduced intoa die assembly having a height of 0.13 m, a width of 0.15 m, and alength of 1 m, and comprising a plurality of spinnerets having a holediameter of 0.305 mm, wherein the number of spinneret holes through thedie was 1378 spinneret holes per linear meter.

[0119] The molten polymer exited the die assembly and entered into acurtain of process air having an air temperature of 260° C. and an airspeed of 366 cfm. The curtain of process air attenuated the extrudedfibers as the fibers traveled a distance d (d=230 mm) from an exit ofthe plurality of spinnerets to a collection surface on an outer surfaceof a rotating drum having an outer diameter of 0.66 m. The drum wasrotating with a linear speed of 40 m/min.

[0120] The plurality of fibers moved along an outer surface of therotating drum having a wire screen contact surface. The formed web wasremoved from the drum by a nip roll assembly.

EXAMPLE 2 Preparation of an Absorbent Meltblown Web

[0121] A fiber-producing melt was prepared by melting a fibercomposition comprising polypropylene at a melt temperature of about 270°C. The polymer melt was extruded a rate of 100 kilograms per hour perlinear meter of extrusion width (kg/hr/lm) using an apparatus similar tothe apparatus as shown in FIG. 4. The molten polymer was introduced intoa die assembly having a height of 0.13 m, a width of 0. 15 m, and alength of 1 m, and comprising a plurality of spinnerets having a holediameter of 0.305 mm, wherein the number of spinneret holes through thedie was 1378 spinneret holes per linear meter.

[0122] The molten polymer exited the die assembly and entered into acurtain of process air having an air temperature of 260° C. and an airspeed of 366 cfm. The curtain of process air attenuated the extrudedfibers as the fibers traveled a distance d (d=230 mm) from an exit ofthe plurality of spinnerets to a collection surface on an outer surfaceof a rotating drum having an outer diameter of 0.66 m. The drum wasrotating with a linear speed of 40 m/min.

EXAMPLE 3 Preparation of a Pre-Stretched Composite Material Comprisingan Abrasive Meltblown Web Bonded to an Absorbent Meltblown Web

[0123] The abrasive meltblown web formed in Example 1 was bonded to theabsorbent meltblown web formed in Example 2 by passing both webs througha calendering process. The abrasive meltblown web/absorbent meltblownweb was then point-bonded to produce a bonded pre-stretched compositehaving a bond cover area of about 33% based on a total surface area ofthe bonded pre-stretched composite.

EXAMPLE 4 Preparation of a Stretched Composite Material Comprising anAbrasive Meltblown Web Bonded to an Absorbent Meltblown Web

[0124] The pre-stretched composite material formed in Example 3 waslaterally stretched in a stretching apparatus as shown in FIGS. 7A-7B.The final nonwoven composite material had a final width 20% greater thanthe width of the bonded pre-stretched composite.

[0125] The composite material had the following properties as shown inTable 1 below. TABLE 1 Test Data for Pre-Stretched and Post-stretchedComposites Pre-stretched Post-stretched % Change Basis Weight 110  99−10% (gsm) Thickness (mm)  0.439  0.642   46% Absorbency (% 322 402  25% dry weight) Drape Good drape in Slightly improved +Change machinemachine direction direction, poor drape drape, greatly in cross improvedcross direction. direction drape Hydro-head (psi) >3 psi 2.6 psi −13%

[0126] As shown in Table 1, microstretching provided the benefits ofincreased material thickness and bulk, increased absorbency, and alsoimproved drape and softness.

EXAMPLE 5 Preparation of a Stretched Wipe Composite Material Containinga Colorant, a Scent-Producing Agent, and a Surfactant

[0127] The stretched composite material formed in Example 4 was spraycoated with a scent-producing agent, Lemon Citrus #50-3264, availablefrom Cognis Corporation (Ambler, Pa.) and a detergent, Detergent0240-82, also available from Cognis Corporation (Ambler, Pa.). Thecoated composite material was dried to form a coated, stretched wipecomposite material having a desired scent and enhanced cleaningcapabilities.

[0128] While the specification has been described in detail with respectto specific embodiments thereof, it will be appreciated that thoseskilled in the art, upon attaining an understanding of the foregoing,may readily conceive of alterations to, variations of, and equivalentsto these embodiments. Accordingly, the scope of the present inventionshould be assessed as that of the appended claims and any equivalentsthereto.

What is claimed is:
 1. A composite material comprising: (a) an outerabrasive layer comprising a first meltblown nonwoven fabric; and (b) atleast one additional fabric bonded to the outer abrasive layer, whereinthe composite material contains a plurality of microstretched portionsextending along a machine direction of the composite material resultingfrom microstretching the (a) the outer abrasive layer, (b) the at leastone additional nonwoven fabric, or both (a) and (b) in a crossdirection.
 2. The composite material of claim 1, wherein the firstmeltblown fabric comprises polypropylene fibers, the at least oneadditional fabric comprises a second meltblown fabric comprisingpolypropylene fibers, and the plurality of microstretched portionsresult from microstretching both (a) and (b) in a cross direction. 3.The composite material of claim 1, wherein the first meltblown fabriccomprises polypropylene fibers, the at least one additional fabriccomprises a spunbonded fabric comprising polypropylene fibers, and theplurality of microstretched portions result from microstretching (b) ina cross direction.
 4. The composite material of claim 2, wherein thefirst meltblown fabric has a basis weight of from about 28 grams persquare meter (gsm) to about 70 gsm, and comprises polypropylene fibershaving an average fiber diameter of from about 10 microns (μm) to about40 μm; and the second meltblown fabric has ⁻a basis weight of from about15 gsm to about 190 gsm, and comprises polypropylene fibers having anaverage fiber diameter of from about 0.5 microns (μm) to about 40 μm. 5.The composite material of claim 1, wherein the first meltblown fabricand the at least one additional fabric are point bonded to one anotherwith a bond area of from about 8% to about 50% based on a total outersurface area of the composite material prior to point bonding.
 6. Thecomposite material of claim 3, wherein the first meltblown fabric isoverblown onto the spunbonded fabric.
 7. The composite material of claim1, wherein the composite material has a wave-like cross-sectionalconfiguration along a cross direction of the composite material, whereinthe wave-like cross-sectional configuration contains a plurality ofalternating peaks and valleys.
 8. The composite material of claim 7,wherein each peak has a peak width measured along the cross direction ofthe composite material and located substantially within a first plane,and each valley has a valley width measured along the cross direction ofthe composite material and located substantially within a second planeparallel with and below the first plane; and wherein the microstretchedportions are located substantially between the first plane and thesecond plane.
 9. The composite material of claim 7, wherein an averagefirst distance between adjacent peaks ranges from about 1.0 mm and about10.0 mm, and an average second distance between adjacent valleys rangesfrom about 1.0 mm and about 10.0 mm.
 10. The composite material of claim7, wherein the peak width is substantially the same for each peak withinthe plurality of peaks, and the peak width ranges from about 0.1 mm toabout 3.0 mm, and wherein the valley width is substantially the same foreach valley within the plurality of valley, and the valley width rangesfrom about 0.1 mm to about 3.0 mm.
 11. The composite material of claim8, wherein the microstretched portions have an average width as measuredalong the cross direction of the composite material between the firstplane and the second plane ranging from about 0.5 mm to about 6.0 mm.12. The composite material of claim 7, wherein the peaks and valleyshave a higher concentration of bonds between the first meltblown web andthe at least one additional fabric compared to a bond concentration inthe microstretched portions.
 13. The composite material of claim 1,wherein at least one layer of the composite material further comprisesone or more additives, wherein the one or more additives comprise acolorant, a scent-producing agent, a surfactant, an antimicrobial agent,or a combination thereof.
 14. The composite material of claim 2, whereinthe second meltblown fabric further comprises one or more additives,wherein the one or more additives comprise a colorant, a scent-producingagent, a surfactant, an antimicrobial agent, or a combination thereof.15. A stack of separate individual sheets, wherein each individual sheetcomprises the composite material of claim
 1. 16. A roll of connectedindividual sheets, wherein each individual sheet comprises the compositematerial of claim
 1. 17. A method of making the composite material ofclaim 1, said method comprising: bonding meltblown fibers to at leastone additional fabric to form a bonded pre-stretched composite; andstretching the bonded pre-stretched composite in a cross direction ofthe bonded composite material to form a plurality of microstretchedportions extending along a machine direction of the composite material.18. A wipe material comprising: (a) an outer abrasive layer comprising afirst meltblown nonwoven fabric; (b) a second nonwoven fabric bonded tothe outer abrasive layer; and (c) one or more additives in the outerabrasive layer (a), the second nonwoven fabric (b), or both (a) and (b),wherein the one or more additives comprise a colorant, a scent-producingagent, a surfactant, an antimicrobial agent, or a combination thereof;and wherein the wipe material contains a plurality of microstretchedportions extending along a machine direction of the wipe materialresulting from microstretching (a), (b), or both (a) and (b) in a crossdirection.
 19. The wipe material of claim 18, wherein the firstmeltblown fabric has (i) a basis weight of from about 28 gsm to about 70gsm, (ii) comprises polypropylene fibers having an average fiberdiameter of from about 10 microns (μm) to about 40 μm, and (iii) issubstantially free of the one or more additives; and the second nonwovenfabric (i) has a basis weight of from about 15 gsm to about 190 gsm,(ii) comprises polypropylene fibers having an average fiber diameter offrom about 2 microns (μm) to about 40 μm, and (iii) comprises one ormore additives, wherein the one or more additives comprise a combinationof a colorant, a scent-producing agent, a surfactant, and anantimicrobial agent.
 20. The wipe material of claim 18, wherein thefirst meltblown fabric and the second nonwoven fabric are point bondedto one another with a bond area of from about 8% to about 50% based on atotal outer surface area of the wipe material prior to point bonding.21. The wipe material of claim 18, wherein the wipe material has awave-like cross-sectional configuration along a cross direction of thewipe material, wherein the wave-like cross-sectional configurationcontains a plurality of alternating peaks and valleys; wherein each peakhas a peak width measured along the cross direction of the wipe materialand located substantially within a first plane, and each valley has avalley width measured along the cross direction of the wipe material andlocated substantially within a second plane parallel with and below thefirst plane; and wherein the microstretched portions are locatedsubstantially between the first plane and the second plane.
 22. The wipematerial of claim 21, wherein an average first distance between adjacentpeaks ranges from about 1.0 mm and about 10.0 mm; an average seconddistance between adjacent valleys ranges from about 1.0 mm and about10.0 mm; the peak width is substantially the same for each peak withinthe plurality of peaks, and the peak width ranges from about 0.1 mm toabout 3.0 mm; and wherein the valley width is substantially the same foreach valley within the plurality of valley, and the valley width rangesfrom about 0.1 mm to about 3.0 mm.
 23. The wipe material of claim 21,wherein the microstretched portions have an average width as measuredalong the cross direction of the wipe material between the first planeand the second plane ranging from about 0.5 mm to about 6.0 mm.
 24. Astack of separate individual wipes, wherein each individual wipecomprises the wipe material of claim
 18. 25. A roll of connectedindividual wipes, wherein each individual wipe comprises the wipematerial of claim
 18. 26. A composite material comprising: (a) an outerabrasive layer comprising a first meltblown nonwoven fabric having abasis weight of from about 28 gsm to about 35 gsm, and comprisingpolypropylene fibers having an average fiber diameter of from about 20microns (μm) to about 40 μm; and (b) a second fabric bonded to the outerabrasive layer, wherein the second fabric has a basis weight of fromabout 30 gsm to about 70 gsm, and comprises polypropylene fibers havingan average fiber diameter of from about 2 microns (μm) to about 20 μm;and (c) one or more additives in the outer abrasive layer (a), thesecond fabric (b), or both (a) and (b), wherein the one or moreadditives comprise a colorant, a scent-producing agent, a surfactant, anantimicrobial agent, or a combination thereof.
 27. The compositematerial of claim 26, wherein at least one layer of the compositematerial contains a plurality of microstretched portions extending alonga machine direction of the composite material resulting frommicrostretching the at least one layer in a cross direction.
 28. Thecomposite material of claim 27, wherein the composite material has across-sectional configuration along a cross direction of the compositematerial, wherein the cross-sectional configuration contains a pluralityof alternating peaks and valleys; wherein each peak has a peak widthmeasured along the cross direction of the composite material and locatedsubstantially within a first plane, and each valley has a valley widthmeasured along the cross direction of the composite material and locatedsubstantially within a second plane parallel with and below the firstplane; and wherein the microstretched portions are located substantiallybetween the first plane and the second plane.